Porcelain is often associated with sublime aesthetic and incredibly sophisticated design potential, however, this durable material can withstand a lot. In fact, the white, shiny exterior of the Porcelain Tower of Nanjing, built in the 15th century with porcelain bricks, is still glistening in the sun to this day. “Still intact, and just as beautiful,” Anton Bourtsev, Director of Kaolin, says with a smile. “Really, there is no life expectancy on porcelain tiles.”
While the lifespan of Kaolin’s porcelain tiles may be infinite, each of their products can be easily traced back to their very beginning, deep under the surface of the ground where clay, feldspar and quartz are sourced. “They are Earth’s most abundant minerals,” Anton explains. “You may be able to find at least a couple of them in your own backyard,” he adds with a smile. Kaolin certainly does - all the minerals they use are sourced within a radius of 300 km from their factory.
This proximity of their suppliers means quality control and minimal logistical issues. “You can simply go to our clay supplier and have a look at the operations for yourself,” Anton says. From the clay suppliers - who, like Kaolin, hold all relevant certifications – to the Kaolin factory, the transformation of these materials is managed through their state-of-the-art manufacturing facility. It’s then stored in a fully automated warehouse; facilities that have achieved numerous environmental certifications in Australia, as well as China. Anton explains that they look more like laboratories than any traditional idea of a factory.
“Everything is automated, which allows us to further reduce our footprint sixfold,” Kaolin’s Director says. Introducing smart solutions has improved not only Kaolin’s accuracy but also the safety profile of the facilities. “There are only robots there - no forklifts driving around, running the risk of crashing into each other.”
This technologically advanced facility is where all of Kaolin’s products are stocked - which Anton and his team choose to do because of sustainability considerations. “We don’t want to stock products here so that we don’t have to waste additional resources - and so that we don’t run the risk of generating waste if the products don’t sell,” Anton explains. Instead, everything is in stock and all Kaolin products are available in under eight weeks. “Guaranteed,” he adds.
Kaolin’s resolve not to generate waste is certainly underpinned by the qualities of the material the company works with. “Porcelain is highly recyclable and can be used in many applications,” he says. He adds that the factory recycles water, waste, and even dust produced in the process of manufacturing. “We capture it and put it back into production,” says Anton. ”It’s very easy to reuse.”
A unique and important part of every tile is the fact that it’s assigned an individual number. “It’s like a birthmark,” Anton smiles. This distinction is what genuinely sets Kaolin apart, as it allows the consumer to trace the product back all the way to the production line, production time - and even the place the clay was sourced from. “Buying our product, you know exactly where it came from,” Anton says. “With Kaolin, there is no middle man - which is often where traceability gets lost. The kind of traceability we offer, raises the bar for the industry and we’re incredibly proud of it.”
Kaolin’s commitment to ethical manufacturing, outstanding quality, and 100% sustainability with unmatched traceability, proves that the notion of modern craftsmanship can successfully combine the qualities traditionally associated with small-scale craftsmanship. It can have a positive impact on the global sustainability agenda. “Generally, people consider there to be these two extremes - mass production and handmade craft,” Anton says “But we believe that you can bring those attributes usually associated with craft - such as passion, quality, attention to details and beauty - to a factory setting.”
Kaolin’s philosophy is a true embodiment of this concept. Most of the company’s engineers graduated from the University in Jingdezhen, known as the “Porcelain Capital.” Jingdezhen has been a manufacturing hub for this beautiful material for over 1,000 years. “Kaolin, which is a type of white, soft porcelain clay, was practically invented in this area,” Anton adds. The trailblazing tile company takes great pride in harnessing the knowledge, expertise and tradition of the region in creating outstanding products - and the fact that their tiles are produced in an automated factory - rather than by hand, in a small workshop - doesn’t take away from these qualities. In fact, Anton points out, it augments the environmental impact of their operations.
“We’re up against the perception of mass production and factory operations; there is still this image of huge chimneys producing lots of smoke and waste,” Anton says. As pioneers in this regard, Kaolin is focused on educating people, opening their minds, and getting them to ask questions of suppliers.
“In the context of sustainability, we’re doing all we can to dispel the negative connotation with mass production,” Anton starts. “Because when you buy that handmade, beautifully made product, its impact on sustainability on a global scale is quite minimal. And there is nothing wrong with that, of course. But if you buy sustainable material in mass or in large quantities, the contribution to the global sustainability agenda can be much more substantial - you can really make a big difference to the environment.”
Anton adds that - naturally - mass produced products will be more affordable which makes the contribution to global sustainability efforts much more attainable. That, in turn, empowers more designers, specifiers and private home owners to have a more pronounced contribution to the world-wide efforts to advance the sustainability profile of the construction industry - and build a more sustainable future for all, one porcelain tile at a time.
